Nozzle insert for an arc welding apparatus

Abstract

A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip.

What is claimed is: 
     
       1. An arc welding apparatus comprising:
 a handle; 
 a conductor tube attached to the handle; 
 a welding cable that carries welding current, shield gas, and a welding wire, the welding cable being connected to the handle; and 
 a consumable assembly attached to the conductor tube, the consumable assembly comprising: 
 a nozzle assembly comprising a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator, the nozzle insert comprising an internal gas diverter and a seating surface; and 
 a contact tip disposed within the nozzle assembly, the contact tip defining a shoulder that engages the seating surface of the nozzle insert and the contact tip further comprising at least one aperture extending from an exterior surface into an internal cavity; and 
 wherein the internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip. 
 
     
     
       2. The arc welding apparatus according to  claim 1 , wherein the internal gas diverter includes a profiled diverter orifice that surrounds the contact tip and the profiled diverter orifice includes a geometry for directing shield gas exiting the at least one aperture of the contact tip. 
     
     
       3. The arc welding apparatus according to  claim 2 , wherein the profiled diverter orifice extends around the at least one aperture of the contact tip. 
     
     
       4. The arc welding apparatus according to  claim 2 , wherein the profiled diverter orifice directs the shield gas exiting the at least one aperture of the contact tip around the exterior surface of the contact tip. 
     
     
       5. The arc welding apparatus according to  claim 2 , wherein the nozzle insert further comprises a body defining a longitudinal axis having a proximal end portion, a distal end portion, and a central bore extending from the proximal end portion towards the distal end portion. 
     
     
       6. The arc welding apparatus according to  claim 5 , wherein the profiled diverter orifice further defines a chamfer at an angle relative to the longitudinal axis of the body. 
     
     
       7. The arc welding apparatus according to  claim 5 , wherein the profiled diverter orifice extends at an angle to, and a length along, the longitudinal axis. 
     
     
       8. The arc welding apparatus according to  claim 1 , wherein the nozzle insert further defines a plurality of threads for securing the nozzle assembly to the conductor tube. 
     
     
       9. The arc welding apparatus according to  claim 8 , wherein the nozzle assembly threadably attaches to the conductor tube by the nozzle insert, and the nozzle insert engages against the shoulder of the contact tip with the seating surface and secures the contact tip to the conductor tube. 
     
     
       10. The arc welding apparatus according to  claim 9 , wherein the conductor tube further comprising a spherical tapered seat and the nozzle insert secures the contact tip into the spherical tapered seat. 
     
     
       11. The arc welding apparatus according to  claim 1 , wherein the nozzle insert comprises one selected from a metal, a metal alloy, or a brass alloy that is capable of withstanding an amperage applied to the consumable assembly and the heat generated during the use of the arc welding apparatus. 
     
     
       12. The arc welding apparatus according to  claim 11 , wherein the nozzle insert is manufactured by one of a machining operation or a metal injection molding. 
     
     
       13. The arc welding apparatus according to  claim 1 , wherein the nozzle body further includes a proximal opening, a distal opening opposite the proximal opening, a convergent section, a divergent section, and a throat section, the divergent section being disposed more proximate to the distal opening than the convergent section and the throat section, and the convergent section being disposed more proximate to the proximal opening than the divergent section and the throat section. 
     
     
       14. The arc welding apparatus according to  claim 13 , wherein the nozzle body further includes an interior diverter surface disposed in the convergent section that directs shield gas into the throat section. 
     
     
       15. The arc welding apparatus according to  claim 13 , wherein the convergent section has a first diameter and the throat section has a second diameter, the first diameter being greater than the second diameter. 
     
     
       16. The arc welding apparatus according to  claim 15 , wherein the divergent section includes a third diameter that increases in size from the throat section to the distal opening of the nozzle body. 
     
     
       17. An arc welding apparatus comprising:
 a handle; 
 a conductor tube attached to the handle; 
 a welding cable that carries welding current, shield gas, and a welding wire, the welding cable being connected to the handle; and 
 a nozzle assembly attached to the conductor tube and configured to secure a contact tip to the conductor tube, the nozzle assembly comprising: 
 a nozzle body having a distal opening and an opposite proximal opening, 
 an insulator disposed within the nozzle body, and 
 a nozzle insert disposed within the insulator, the nozzle insert defining a longitudinal axis and having a proximal end portion, a distal end portion, and a central bore extending from the proximal end portion towards the distal end portion, the insert further comprising: 
 an internal gas diverter disposed proximate to the distal end portion of the nozzle insert, the internal gas diverter defining a seating surface facing toward the proximal end portion and a profiled diverter orifice, wherein the profiled diverter orifice is defined by a surface facing toward the distal end portion of the body, the surface extending radially outward from the longitudinal axis along a length of the surface toward the distal end portion, the length of the surface extending distally from the central bore to the distal end portion. 
 
     
     
       18. The arc welding apparatus according to  claim 17 , wherein the profiled diverter orifice surrounds the contact tip and the profiled diverter orifice includes a geometry for directing shield gas exiting at least one aperture of the contact tip around an exterior surface of the contact tip. 
     
     
       19. An arc welding apparatus comprising:
 a handle; 
 a conductor tube attached to the handle; 
 a welding cable that carries welding current, shield gas, and a welding wire, the welding cable being connected to the handle; and 
 a consumable assembly attached to the conductor tube, the consumable assembly comprising: 
 a nozzle assembly comprising a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator, the nozzle insert comprising a distal end portion, a proximal end portion, and an internal gas diverter disposed proximate to the distal end portion, the internal gas diverter comprising: 
 a profiled diverter orifice having a surface facing toward the distal end portion and extending radially outward from a longitudinal axis of the nozzle insert along a length of the surface toward the distal end portion, and 
 a seating surface facing toward the proximal end portion; and 
 a contact tip disposed within the nozzle assembly, the contact tip defining a shoulder that engages the seating surface of the nozzle insert, the contact tip further comprising at least one aperture extending from an exterior surface into an internal cavity; and 
 wherein the profiled diverter orifice directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip. 
 
     
     
       20. The arc welding apparatus according to  claim 19 , wherein the nozzle insert further defines a plurality of threads for securing the nozzle assembly to the conductor tube, the nozzle insert engages against the shoulder of the contact tip with the seating surface to secure the contact tip to the conductor tube.